RS fabrications

Marussia Virgin Racing and RS Fabrications came together in Barcelona at the recent Catalunya Circuit F1 Test.

Under the intense Formula 1 manufacture, testing and racing schedule, RS Fabrications have helped in the manufacture of fabricated components on the MVR-02 and Pit Lane equipment that will be used in anger during the 2011 season.

Dave O,Neill, Team Manager at Marussia Virgin Racing, had specific requirements and Russell joined the team in Barcelona to iron out the finer details of the requests, the main focus being the Pit Garage and Pit Lane set-ups.

“Having worked with Wirth Reserch on components for the MVR-02, it was good to see the car in action at Catalunya”, commented Russell, ” we have also had involvement with equipment associated with the set up of the chassis and the MVR teams pitstop configuration. Andor has been ‘flat out’ with CAD design work back in the Design Office and Shane has had some late nights with the welding duties”.

With the Cosworth powered F1 Car being driven by Jerome D’Ambrosio, the team had a number of runs to gather data, at one stage running a simulated GP length run to monitor vehicle systems and run through race simulated pitstops.

All went well, and RS Fabrications will continue their support and association with Marussia Virgin Racing well into the upcoming Formula 1 season.

Steve Smee’s Ulitima moves another step forward.

Steve, frustrated with progress, is looking forward to getting the old “Snuff” back up and running with the new RS6 Engine.

With the flywheel trigger complications recently, progress has been slow, but we expect to get the vehicle down to MRC Tuning by the end of this upcoming week.

New man, Colin Chapman, [ex Prodrive Engineer] has been meticulous in the assembly of all components to ensure Steve Smee & MRC Tuning will not have problems with the Ultima down the road. In the past 2 weeks the Transaxle, engine & gearbox, have been in & out of the chassis on numerous occasions, sorting out small installation issues.

With extensive chassis modification, bespoke flywheel, manifolds [ceramic coated], Silencers, Fuel Tank, Intercoolers, to name the larger items, this week we expect to finish the Turbo charge pipes & water system.

Its then down to MRC Tuning to get the wiring sorted and Minea to do his “magic” with the ECU Map and running of the vehicle!

“This is not a road car, but a racing car that happens to be street legal”!! commented Russell, “Steve is going to be very happy with the results, but at the moment he is very frustrated with progress”

Updates to follow.

Associated websites:-

http://www.mrctuning.com/

http://www.ultimasports.co.uk/Default.aspx

Local Banbury car enthusiast Robert, wanted an aluminium radiator for his Zetec engined Fury sportscar.

The Fury, manufactured by Fischer Sportscars, is a well designed chassis and suspension assembly, giving superb handling and road holding prowess and combined with the modern Zetec engine technology provides Robert with a fantastic sportscar package.

An aluminium radiator core was purchased and Shane fabricated the tanks to build a duel pass radiator. This configuration is having the inlet & outlet on the same end. This allows the cooling liquid to enter at one end, pass across the radiator core, turn180 degrees, pass back across  the core and exit.

A temperature switch boss was added, along with a new electric fan to complete the radiator installation.

Shane then finished the water system with custom Aluminium water pipes.

Robert was very happy with the outcome,  you could tell by the amount of rubber that he left in the RS Fabrications car park!!

Ellis Harvey collected another Trophy to add to the Trophy Cabinet at RS Fabrications.

Riding for RS Fabrications & Banbury Motorcross Club, Gunner Harvey finishing just outside the top 10 , with a 12 place Trophy in the Schoolboy Summer Championship 2010.

“I had some tough opposition this year and some major crashes”, commented Ellis ” but 2011 is going to be my year, my last before I upgrade to a larger capacity bike”!

The RS Fabrications Works Honda CR85 will be totally rebuilt through the winter months in preparation for 2011 to give Ellis the best opportunity for next season.

The RS Fabrications VW T5 Support Vehicle, is also undergoing a full rebuild after an unfortunate collision on the A34.

We will be following Ellis Harvey’s progress, and provide him with the equipment required for 2011 Championship.

After a meeting with Gabriel Uttley at the workshop in Banbury last week, RS fabrications are on board for the 400 MPH Land Speed Record attempt with the Angelic Bulldog Project.

Gabriel is totally committed to this attempt and is using British Engineering Companies to hep him achieve his goal and bring the Motorcycle Land Speed Record back to Britain, last achieved in 1937.

http://www.angelicbulldog.org.uk/news/

http://www.angelicbulldog.org.uk/2010/10/18/rs-fabrications/

“Its great to be able to help Gabriel with his Motorcycle Land Speed  attempt and we are taking up the duties with the exhaust system and other CNC Machined  Engine components,” said Russell ” and the engine configuration is based on Twin  Honda Blackbird Units. At 2272cc + superchargers & Nitrous, the bike will be putting out up to 700 BHP for the anticipated 56sec runs on the salt flats”.

Design is to be finalised on the system, but with Twin Ceramic Coated, 4 into 1 manifolds, leading in to racing merged collectors, will be exiting through the rear of the bike,  so RS Fabrications are literally behind every aspect of this challenge!!

Engines are coming together and once they are installed in the Chassis the bike will come down to RS Fabrications in Banbury to have the Exhaust System fabricated.

We will be following the project to completion and be with Gabrial and his team every MPH of the way!!

Associated Websites:-

http://www.angelicbulldog.org.uk/

http://www.youtube.com/watch?v=oyavpCJz0Sk

http://www.youtube.com/watch?v=dm1tfqXIY9w

Joey Smith, one of the Smiths of Bloxham Boys, dropped into RS Fabrications to get “measured up” for a system on his 5 Series BMW M Sport.

Joey was after the M5 look with the 4 rear tailpipe set-up.

A replacement Carbon Fibre rear panel was purchased and the BMW was booked in.

Joey had his mate Blue, local bodyshop repair and vehicle painter, finish the carbon panel in body colour and then this was fitted into the rear bumper of the 5 Series.

A single silencer box system was fabricated in stainless steel with the 4  racing style Tailpipes exiting through the apertures on the new carbon panel.

Joey is really happy with the results, ” Cruising in the 2.5 Diesel the exhaust purrs, but when you put your foot in it, the benefits can really be appreciated!” said Joey.

Next on the list for Joey is a re-map, and that should really get things moving!!

Call Russell or Shane to get your RS Fabrications M Power!

Local Banbury Lad Carlos Lane, knows quality and knew what he wanted for his Subaru.

Shane specified a twin box  full stainless steel system with Carlos opting for a 4″ Rolled In Polished tailpipe to finish it off.

With the original system removed, the new performace item was hand fabricated between Shane & Tony, with Shane finish welding the purged system to his normal high standard.

Whether its a road car or a full blown racing car, you get the same quality at RS Fabrications.

Carlos was over to moon texting Russell “Hi, I am extremly happy with my exhaust Russell, thanks very much and thank Shane, he has done a fantastic job, well pleased!”

Now if we could just get Conrad’s AE86 on its wheels we would be laughing!!

Look out for an update on Conrad’s  extensively modified AE 86 this month.

John brought his Dodge Ram Dually to RS Fabrications for a custom rear bumper & sidebars.

Having sustained a rear impact accident in the snow last year, the rear of the Dually was stripped out and checked for chassis damage and then Shane took on the duties of fabricating a custom rear bumper in Mirror Polished Stainless Steel.

3 inch side bars, again in Mirror Polished Stainless Steel, were mandrel bent and installed on each side of the Dually Pick-up.

Fog Lights and Reversing lights also sustained damage in the accident and round Hella LED rear lights have been used to replace the damaged items.

These modern Hella units consist of an outer ring of red LED Running Lights, and the centre lenses, one red pair for fog and the other clear for reversing ,centred in the units.

It’s a nice touch and a clean finish to the polished rear bumper.

Please Call for your Custom Truck Requirements on 01295 266655

An Audi RS6 Sportwagon with a Lamborghini V10 engine  [kicking out 760 BHP  courtesy of MRC Tuning] sitting upfront, needs something to slow it down!

John contacted RS Fabrications to install bigger Dia Rear Disc’s and large 4 pot rear Calipers to his Estate Car.

Johns RS6 had been into RS Fabrications, prior to the MRC Tuning work, to have the larger Dia front disc’s and 6 pot Calipers mounted to the front end, which was pretty straight forward in engineering terms.

The rear was a different matter, due to the factory installation of electronic parking brake servos, and limited room around the rear suspension, disc and driveshaft.

Andor [Cad/Design Engineer] produced files for the intended installation, completing the engineering to put the 4 Pot Calipers behind the axle center and mounting the original caliper on the top just forward of the centre line. Everything has to sit behind the 20″ OZ custom wheels.

The first problem with this was clearance around the suspension components, and the factory brake servos had to be modified. This caused more problems than was initially anticipated.

With a 50% loss rate in servo modification, RS Fab lost the original pair of servos!  This played havoc with the Control Module on the vehicle and a complete reboot of the vehicle control systems was required.

A 2 part duel caliper mount was manufacture in EN24T Steel material, incorporating the factory mounts on the rear upright.  This was required to locate the 4 Pot caliper and the factory electronic handbrake mechanism around the rear suspension set-up..

” I lost sleep over this installation and the problems that we had with the factory rear handbrake servos”, said Russell. ” They said that it couldn’t be done, and they were nearly right”!!

“We destroyed 2 servo motors, during the modifications to get them to actually fit the vehicle, but this is the price you pay for upgraded brake conversions & development of this nature” continued Russell, ” This car has ‘savage’ acceleration & speed, and now it is equipped with the braking capacity to ‘keep it on the island’. Road Tests were very interesting !”

Task completed, John was eager to get his RS6 back into the Stable, this was after an extended period of time, but he was toatally happy with the results.

Sometimes what might seem impossible, is possible!!

Call Russell or Shane on 01295 266655 and get the power. In this case, Stopping Power!!

Jason Tubb came to RS Fabrications to get the final touches to his immaculate GT40.

3 years in the creation, Jason wanted the perfect exhaust system to complete the engine bay in the vehicle.

Jason has painstakingly put this GT 40 together, starting with a Stainless Steel Chassis and systematically working through each item and finishing each part to the highest standard, so it was a “no brainer” on where to get the exhaust made!

Bends were mandrel bent in 1.75″ 316 Stainless Steel and laser cut flanges ordered, digitised from the manifold gaskets supplied.

Tooling was made to press the profile onto the ends of the primary tubes that exit the cylinder head, and a pair of short 4 into1 Murged Collectors fabricated.

3.0″ silencers with 4.0″ tailpipes exit the system through the bodywork at the rear of the vehicle and additional removable  Plug Silencers manufactured, to provide the option to run under 98dB for track use.

Shane put the tuned length system together based on some original drawings, and with CAD files supplied by Andor, to identify the required firing order.

Jason was over the moon once it was fired up, as it was the 1st time he had heard it run with a complete exhaust system.

Next stop was off the get the carbs set up, then to the SVA, to get the tests and paperwork sorted for the registration of this fantastic GT 40.

Nice one Jason!!

Check it out on You Tube:-

http://www.youtube.com/watch?v=xDvhlOTjXIo